A Project-Based Approach to Control Systems

In the world of industrial automation, a common challenge is translating a client's needs from a detailed project scope into a working system. This workshop tackles that challenge head-on by providing a unique learning experience based on a real-world scenario. Instead of just teaching theoretical concepts, we use a comprehensive project scope document for an existing pump mixing system as our "machine."

This isn't a simple simulation; it's a deep dive into the practical application of integration principles. You will learn to navigate the complexities of a real-world project, including:

• SCADA and HMI Development: We'll start by building the human-machine interface, just as you would for a physical machine. This includes designing screens with controls, graphics, and alarms that directly address the client's requirements.

• Data Management: You'll build the framework for data logging, trending, and reporting. The project scope details specific data points to track, such as pump runtime, OEE, and energy usage, giving you a clear objective to work toward.

• Security and User Management: You’ll to configure user authentication, roles, and permissions to ensure system security. This is crucial for real-world applications where different users have varying levels of access.

• Communication Protocols: You’ll connect to external devices including Allen Bradley and Siemens PLCs using common protocols including Ethernet/IP, Modbus, and OPC-UA.

• Web Development & Mobile Integration: Show how to create web-based dashboards and integrate with mobile devices. This aligns with modern SCADA trends and makes the training more relevant.

By focusing on a detailed project scope rather than a physical machine, this workshop allows you to concentrate on the crucial skills of planning, design, and implementation. You will learn to read between the lines of a client's request, identify potential issues, and build a robust, scalable solution. By the end, you'll have the confidence to approach a new integration project, knowing you can turn a document into a functioning system.

Skills that you will learn.

HMI/SCADA Development:

• Downloading and installing Inductive Automation’s Ignition

• Creating a basic operator screen such as start, stop, and tank level indicators.

• Designing a settings screen to adjust parameters.

• Building an alarms screens.

• Best practices for screen navigation

• Developing graphical indicators.

• Adding real-time input and output indicators for troubleshooting.

Data Management & Reporting:

• Logging system usage and pump runtime for maintenance.

• Implementing logic for trend data on variables like tank level and pump speed.

• Creating daily system summary reports.

• Adding OEE tracking and energy monitoring features.

• Building a recipe system to load predefined control parameters.

Alarming & Safety:

• Creating alarms and warnings with logic to differentiate them.

• Assigning priorities to critical alarms.

• Developing multiple alarm listings for active, past, and combined alarms.

• Setting up email notifications for specific critical alarms.

• Implementing safety-related alarms for E-stops and drive faults.